A positive electrode soft copper bar assembly convenient to install

Abstract

The utility model discloses a positive pole soft copper bar assembly convenient to installation, including soft copper bar body, hard copper bar connecting end and quick release type connecting piece, soft copper bar body one end is fixedly connected with hard copper bar connecting end, and its other end is free end. Quick release type connecting piece includes the positioning boss of being located on the upper surface of soft copper bar body free end, the positioning recess of being located on the lower surface of hard copper bar connecting end corresponding position, the bolt hole of being penetrated through positioning boss and soft copper bar body, the assembly counterbore of being located on hard copper bar connecting end with bolt hole coaxial and locking bolt. Copper bar free end positioning boss and hard copper bar positioning recess match, and the matching hard copper bar bevel guide does not need repeatedly align, and single assembly time is greatly shortened, and bolt and lock nut combination facilitate quick release, and when maintaining, can only change the wearing spare part, and the service life is longer, and the assembly counterbore can hide bolt head and prevent scratch damage, and the failure occurrence rate is reduced, and is suitable for new energy automobile, energy storage equipment and other scenes.

Description

Technical Field

[0001] This utility model relates to the field of copper busbar technology, specifically to a positive electrode soft copper busbar assembly that is easy to install. Background Technology

[0002] Positive electrode soft copper busbars are key conductive components in high-current transmission scenarios such as new energy vehicles and energy storage equipment. Their ease of installation and electrical reliability directly affect the equipment assembly efficiency and long-term operational stability. Currently, traditional positive electrode soft copper busbar assemblies suffer from several technical defects: First, installation alignment is difficult, requiring repeated adjustments to the bolt holes of the soft and hard copper busbars to achieve coaxiality. This is time-consuming for non-professionals and results in low batch assembly efficiency. Second, connection reliability is poor. Most adopt a spliced ​​structure, with contact resistance often exceeding 15mΩ. Heat loss during current transmission is significant, and bolts are prone to loosening due to equipment vibration, leading to poor contact or even open circuits. Third, insulation protection is insufficient. Relying mainly on insulating tape, which is prone to detachment and short-circuit risks. Furthermore, the lack of a sealed design allows dust and moisture to easily penetrate the connection points, resulting in a failure rate exceeding 12% in environments with temperatures ranging from -40℃ to 85℃ and high humidity. Fourth, the lack of an error compensation structure makes it difficult to adapt to equipment processing tolerances, and the copper busbars are easily damaged by rigid tension, shortening their service life. Utility Model Content

[0003] In order to overcome the shortcomings of existing technical solutions, this utility model provides a positive electrode soft copper busbar assembly that is easy to install, which can effectively solve the problems mentioned in the background art.

[0004] The technical solution adopted by this utility model to solve its technical problem is: A positive electrode soft copper busbar assembly that is easy to install includes a soft copper busbar body, a hard copper busbar connection end, and a quick-release connector. One end of the soft copper busbar body is fixedly connected to the hard copper busbar connection end, and the other end is a free end. The quick-release connector includes a positioning boss on the upper surface of the free end of the soft copper busbar body, a positioning groove on the lower surface of the corresponding position of the hard copper busbar connection end, a bolt hole penetrating the positioning boss and the soft copper busbar body, an assembly countersunk hole coaxial with the bolt hole on the hard copper busbar connection end, and a locking bolt. The positioning boss and the positioning groove are matched in shape and fit together in the assembled state to achieve radial positioning. The locking bolts pass through the bolt holes and countersunk holes in sequence and are tightened by the anti-loosening nuts to achieve axial compression and conductive connection between the soft copper bus body and the hard copper bus connection end.

[0005] As a further description of the above technical solution, the soft copper busbar body is provided with a pre-formed U-shaped bending structure near the free end, and the positioning boss is provided on the top plane of the U-shaped bending structure.

[0006] As a further description of the above technical solution, it also includes an insulation protection component, which includes a first insulating soft sleeve wrapped around the body of the soft copper busbar and a second insulating hard sleeve wrapped around the connection end of the hard copper busbar and adjacent to the first insulating soft sleeve. The first insulating soft sleeve has a first clearance hole at the corresponding positioning boss position, and the second insulating hard sleeve has a second clearance hole at the corresponding positioning groove and assembly countersunk hole positions.

[0007] As a further description of the above technical solution, the adjacent end faces of the first insulating soft sleeve and the second insulating hard sleeve are provided with mutually cooperating annular sealing ribs and annular sealing grooves. When the locking bolt is tightened, the annular sealing ribs are pressed into the annular sealing grooves to form a sealing structure.

[0008] As a further description of the above technical solution, the end of the hard copper busbar connection is provided with an outwardly expanding inclined guide portion.

[0009] As a further description of the above technical solution, the positioning boss is rectangular, and its height is greater than the depth of the positioning groove.

[0010] As a further description of the above technical solution, the depth of the mounting countersunk hole is greater than the height of the locking bolt head.

[0011] As a further description of the above technical solution, the soft copper busbar body and the hard copper busbar connection end are fixedly connected by welding or integral molding.

[0012] Compared with the prior art, the beneficial effects of this utility model are: The present invention provides an easy-to-install positive electrode soft copper busbar assembly, which has at least one of the following beneficial effects during use: In terms of installation, the positioning boss at the free end of the soft copper busbar matches the positioning groove of the hard copper busbar, and with the guide of the inclined surface of the hard copper busbar, repeated alignment is not required, significantly reducing the assembly time per unit. The U-shaped bend of the soft copper busbar can compensate for installation errors, greatly improving the pass rate of batch installations. Even non-professionals can operate it, and the combination of bolts and lock nuts allows for quick and easy disassembly. During maintenance, only vulnerable parts need to be replaced, without disassembling the entire device. In terms of connection and transmission, the soft copper busbar and hard copper busbar are fixed by welding or integral molding, with contact resistance controlled below 5mΩ. At a current of 200A, the heat generation is reduced by about 15W per hour. The lock nuts can resist vibration and temperature changes to prevent bolt loosening, and the U-shaped bend can withstand more than 5000 cycles of deformation, extending the service life. The countersunk holes in the assembly can hide the bolt heads to prevent scratches. In terms of protection, the double-layer insulation sleeve provides high insulation resistance, and the annular sealing structure of adjacent end faces can block dust and moisture, allowing the module to operate stably in an environment of -40℃ to 85℃ and 95% relative humidity, reducing the failure rate and making it suitable for new energy vehicles, energy storage equipment, and other scenarios. Attached Figure Description

[0013] Figure 1 This is a schematic diagram of the overall structure of a positive electrode soft copper busbar assembly that is easy to install according to this utility model; Figure 2 This is a side view of a positive electrode soft copper busbar assembly that is easy to install according to this utility model. Figure 3 This is a schematic diagram of the first part of the structure of a positive electrode soft copper busbar assembly that is easy to install according to this utility model; Figure 4 This is a schematic diagram of the second part of the positive electrode soft copper busbar assembly that is easy to install according to this utility model.

[0014] Numbering on the map: 1. Soft copper busbar body; 11. U-shaped bending structure; 2. Hard copper busbar connection end; 21. Positioning groove; 22. Assembly countersunk hole; 23. Angled guide part; 3. Quick-release connector; 31. Positioning boss; 32. Bolt hole; 33. Locking bolt; 34. Anti-loosening nut; 4. Insulation protection component; 41. First insulating soft sleeve; 42. Second insulating hard sleeve; 421. Annular sealing rib; 422. Annular sealing groove. Detailed Implementation

[0015] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0016] like Figure 1-2 As shown, this utility model provides a positive electrode soft copper busbar assembly that is easy to install, including a soft copper busbar body 1, a hard copper busbar connection end 2 and a quick-release connector 3. One end of the soft copper busbar body 1 is fixedly connected to the hard copper busbar connection end 2, and the other end is a free end. The quick-release connector 3 includes a positioning boss 31 on the upper surface of the free end of the soft copper busbar body 1, a positioning groove 21 on the lower surface of the corresponding position of the hard copper busbar connecting end 2, a bolt hole 32 penetrating the positioning boss 31 and the soft copper busbar body 1, an assembly countersunk hole 22 on the hard copper busbar connecting end 2 coaxial with the bolt hole 32, and a locking bolt 33. The rectangular positioning boss 31 at the free end of the soft copper busbar body 1 matches the shape of the positioning groove 21 at the connecting end of the hard copper busbar 2. During assembly, the boss is first inserted into the groove to directly achieve radial limiting (preventing the copper busbar from shifting or twisting), ensuring that the bolt hole 32 of the soft copper busbar and the mounting countersunk hole 22 of the hard copper busbar are precisely coaxial, avoiding repeated alignment adjustments.

[0017] The inclined guide 23 of the hard copper busbar connection end 2 can guide the boss to quickly embed into the groove, reducing the difficulty of assembly alignment; at the same time, the pre-formed U-shaped bending structure 11 of the soft copper busbar body 1 near the free end has elastic deformation capability, which can compensate for small axial / radial installation errors (such as equipment processing tolerances, vibration displacement), and avoid damage to the soft copper busbar due to rigid tension.

[0018] The positioning boss 31 and the positioning groove 21 are matched in shape and fit together in the assembled state to achieve radial positioning. The locking bolt 33 passes through the bolt hole 32 and the mounting countersunk hole 22 in sequence and is tightened by the anti-loosening nut 34, so as to realize the axial compression and conductive connection between the soft copper bus body 1 and the hard copper bus connection end 2.

[0019] After positioning, the locking bolt 33 passes through the bolt hole 32 of the soft copper busbar and the mounting countersunk hole 22 of the hard copper busbar in sequence, and is tightened with the anti-loosening nut 34. The axial clamping force makes the copper contact surfaces of the soft copper busbar and the hard copper busbar fit tightly, which not only ensures a firm mechanical connection, but also realizes electrical conduction.

[0020] The soft copper busbar body 1 and the hard copper busbar connection end 2 are fixed by welding or integral molding without additional contact gaps, which can control the contact resistance to below 5mΩ (far lower than the 15mΩ of the traditional splicing structure) and reduce heat loss during current transmission; the anti-loosening nut 34 can resist the loosening of bolts caused by equipment vibration and temperature changes, and avoid poor contact or open circuit.

[0021] The depth of the countersunk hole 22 is greater than the height of the head of the locking bolt 33, so that the bolt head is completely hidden in the countersunk hole, preventing scratches and damage, and facilitating subsequent disassembly and maintenance.

[0022] Furthermore, the soft copper busbar body 1 has a pre-formed U-shaped bending structure 11 near the free end, and the positioning boss 31 is disposed on the top plane of the U-shaped bending structure 11.

[0023] The radial positioning of the "boob-groove" and the inclined guide reduce the assembly time by more than 30% (no need for repeated alignment), and even non-professionals can operate efficiently; the combination of bolts and anti-loosening nuts 34 facilitates quick disassembly, and there is no need to disassemble the whole equipment during later maintenance. Only vulnerable parts (such as nuts) need to be replaced, reducing maintenance time and cost.

[0024] The U-shaped bending structure 11 can handle installation errors within ±0.5mm, avoid assembly failures caused by insufficient equipment precision, and improve the pass rate of batch installation (from the traditional 85% to over 99%).

[0025] The U-shaped bending structure 11 can withstand more than 5,000 cycles of deformation (simulating equipment vibration), avoiding fatigue fracture of soft copper busbars and extending mechanical life by 2 times.

[0026] Furthermore, it also includes an insulation protection component 4, which includes a first insulating soft sleeve 41 wrapped around the soft copper bus body 1 and a second insulating hard sleeve 42 wrapped around the hard copper bus connection end 2 and adjacent to the first insulating soft sleeve 41. The first insulating soft sleeve 41 (adapted to the flexible characteristics of the soft copper busbar) wraps around the soft copper busbar body 1, and the second insulating hard sleeve 42 (adapted to the rigidity requirements of the hard copper busbar) wraps around the hard copper busbar connection end 2. The two sleeves have clearance holes at the corresponding positioning bosses 31 and bolt holes 32, which do not affect the core function and isolate the copper busbar from accidental contact with external conductors to prevent electric shock or short circuit.

[0027] The first insulating soft sleeve 41 has a first clearance hole at the position corresponding to the positioning boss 31, and the second insulating hard sleeve 42 has a second clearance hole at the position corresponding to the positioning groove 21 and the assembly countersunk hole 22.

[0028] The double-layer insulation sleeve enables the component to achieve a normal insulation resistance of over 100MΩ and withstand an AC2500V withstand voltage test (without breakdown for 1 minute), solving the safety hazard caused by the easy detachment of insulating tape from traditional copper busbars.

[0029] Furthermore, the adjacent end faces of the first insulating soft sleeve 41 and the second insulating hard sleeve 42 are provided with mutually cooperating annular sealing ribs 421 and annular sealing grooves 422. When the locking bolts 33 are tightened, the annular sealing ribs 421 are pressed into the annular sealing grooves 422 to form a sealing structure.

[0030] The annular sealing ribs 421 and sealing grooves on the adjacent end faces of the two insulating sleeves will be pressed into the grooves by axial pressure when the bolts are tightened, forming a sealed structure. This prevents dust and moisture from entering the copper busbar connection, avoiding insulation failure caused by moisture and contamination of the insulation layer, and ensuring electrical safety. The annular sealing structure enables the components to operate stably in environments ranging from -40℃ to 85℃ and with a relative humidity of 95%, making them suitable for outdoor energy storage, industrial equipment, and other humid / dusty scenarios, thus avoiding failures caused by environmental factors (reducing the failure rate from the traditional 12% to below 2%).

[0031] Furthermore, the end of the hard copper busbar connection end 2 is provided with an outwardly expanding inclined guide portion 23.

[0032] Furthermore, the positioning boss 31 is rectangular, and its height is greater than the depth of the positioning groove 21.

[0033] The height of the positioning boss 31 is greater than the depth of the groove (difference 0.2-0.3mm) to ensure sufficient contact area during fitting and prevent copper busbar wear caused by loose positioning.

[0034] Furthermore, the depth of the mounting countersunk hole 22 is greater than the height of the head of the locking bolt 33.

[0035] Furthermore, the soft copper busbar body 1 and the hard copper busbar connection end 2 are fixedly connected by welding or integral molding.

[0036] The welding / integrated connection method reduces contact resistance, which can reduce heat loss during current transmission (for example, with a current of 200A, the heat loss is reduced by about 15W per hour), avoids ablation faults caused by local overheating, and is suitable for high-current scenarios such as new energy vehicles and energy storage equipment.

[0037] It will be apparent to those skilled in the art that this invention is not limited to the details of the exemplary embodiments described above, and that it can be implemented in other specific forms without departing from the spirit or essential characteristics of this invention. Therefore, the embodiments should be considered illustrative and non-limiting in all respects, and the scope of this invention is defined by the appended claims rather than the foregoing description. Thus, it is intended that all variations falling within the meaning and scope of equivalents of the claims be included within this invention. No reference numerals in the claims should be construed as limiting the scope of the claims.

Claims

1. A positive electrode soft copper busbar assembly that is easy to install, characterized in that: It includes a soft copper busbar body (1), a hard copper busbar connection end (2) and a quick-release connector (3). One end of the soft copper busbar body (1) is fixedly connected to the hard copper busbar connection end (2), and the other end is a free end. The quick-release connector (3) includes a positioning boss (31) on the upper surface of the free end of the soft copper busbar body (1), a positioning groove (21) on the lower surface of the corresponding position of the hard copper busbar connecting end (2), a bolt hole (32) penetrating the positioning boss (31) and the soft copper busbar body (1), an assembly countersunk hole (22) on the hard copper busbar connecting end (2) coaxial with the bolt hole (32), and a locking bolt (33). The positioning boss (31) and the positioning groove (21) are shaped to match each other and fit together in the assembled state to achieve radial positioning; The locking bolt (33) passes through the bolt hole (32) and the mounting countersunk hole (22) in sequence and is tightened by the anti-loosening nut (34) to achieve axial compression and conductive connection between the soft copper bus body (1) and the hard copper bus connection end (2).

2. The easily installable positive electrode soft copper busbar assembly according to claim 1, characterized in that: The soft copper busbar body (1) has a pre-formed U-shaped bending structure (11) near the free end, and the positioning boss (31) is set on the top plane of the U-shaped bending structure (11).

3. The easily installable positive electrode soft copper busbar assembly according to claim 1, characterized in that: It also includes an insulation protection component (4), which includes a first insulating soft sleeve (41) wrapped around the soft copper bus body (1) and a second insulating hard sleeve (42) wrapped around the hard copper bus connection end (2) and adjacent to the first insulating soft sleeve (41). The first insulating soft sleeve (41) has a first clearance hole (411) at the corresponding positioning boss (31) position, and the second insulating hard sleeve (42) has a second clearance hole (421) at the corresponding positioning groove (21) and assembly countersunk hole (22) position.

4. The easily installable positive electrode soft copper busbar assembly according to claim 3, characterized in that: The first insulating soft sleeve (41) and the second insulating hard sleeve (42) are provided with a matching annular sealing rib (412) and an annular sealing groove (422) between their adjacent end faces. When the locking bolt (33) is tightened, the annular sealing rib (412) is pressed into the annular sealing groove (422) to form a sealing structure.

5. The easily installable positive electrode soft copper busbar assembly according to claim 1, characterized in that: The end of the hard copper busbar connection end (2) is provided with an outwardly expanding inclined guide portion (23).

6. The easily installable positive electrode soft copper busbar assembly according to claim 1, characterized in that: The positioning boss (31) is rectangular, and its height is greater than the depth of the positioning groove (21).

7. The easily installable positive electrode soft copper busbar assembly according to claim 1, characterized in that: The depth of the mounting countersunk hole (22) is greater than the height of the head of the locking bolt (33).

8. The easily installable positive electrode soft copper busbar assembly according to claim 1, characterized in that: The soft copper busbar body (1) and the hard copper busbar connection end (2) are fixedly connected by welding or integral molding.

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